Modelling the Effect of Process Conditions on Steering-Induced Defects in Automated Fibre Placement (AFP)

Yi Wang; Sarthak Mahapatra; Jonathan P Belnoue; Dmitry Ivanov; Stephen R Hallett

doi:10.1016/j.compositesa.2023.107702

Modelling the Effect of Process Conditions on Steering-Induced Defects in Automated Fibre Placement (AFP)

Yi Wang, Sarthak Mahapatra, Jonathan P Belnoue, Dmitry Ivanov, Stephen R Hallett

Research output: Contribution to journal › Article (Academic Journal) › peer-review

9 Citations (Scopus)

Abstract

Automated manufacturing of carbon fibre-reinforced polymer composites, such as automated fibre placement (AFP), is widely used in the aerospace industry. Due to the large number of physical and environmental phenomena involved and their (mathematical) nonlinearity, simulating the AFP process under varied processing conditions has, for a long time, been computationally out of reach. This paper discusses how recent advancements in the Finite Element (FE) simulation of steering-induced defects in AFP can allow virtual optimisation of the process prior to physical trials. First, efforts necessary to adequately characterise the material experimentally and constitutive models able to represent the observed behaviour are reviewed. The material models are then incorporated into a simulation platform developed in a commercial FE package. It is shown that the proposed virtual AFP platform has good predictive capabilities against experimental data available from literature. Its potential to capture the influence of processing conditions on layup quality is investigated.

Original language	English
Article number	107702
Journal	Composites Part A: Applied Science and Manufacturing
Volume	173
DOIs	https://doi.org/10.1016/j.compositesa.2023.107702
Publication status	Accepted/In press - 20 Jul 2023

Bibliographical note

Funding Information:
This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) through the Centre for Doctoral Training in Advanced Composites for Innovation and Science (grant no. EP/ L016028/1) and the platform grant “Simulation of new manufacturing Processes for Composite Structures (SIMPROCS)” (grant no. EP/ P027350/1). Yi Wang acknowledges the support from the China Scholarship Council. The authors acknowledge the Chair of Carbon Composites at the Technical University of Munich for providing their AFP simulation model that has inspired this work.

Publisher Copyright:
© 2023 The Authors

Keywords

Automated manufacturing
Automated fibre placement
Manufacturing-induced defects prediction
Thermoset prepreg composites

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title = "Modelling the Effect of Process Conditions on Steering-Induced Defects in Automated Fibre Placement (AFP)",

abstract = "Automated manufacturing of carbon fibre-reinforced polymer composites, such as automated fibre placement (AFP), is widely used in the aerospace industry. Due to the large number of physical and environmental phenomena involved and their (mathematical) nonlinearity, simulating the AFP process under varied processing conditions has, for a long time, been computationally out of reach. This paper discusses how recent advancements in the Finite Element (FE) simulation of steering-induced defects in AFP can allow virtual optimisation of the process prior to physical trials. First, efforts necessary to adequately characterise the material experimentally and constitutive models able to represent the observed behaviour are reviewed. The material models are then incorporated into a simulation platform developed in a commercial FE package. It is shown that the proposed virtual AFP platform has good predictive capabilities against experimental data available from literature. Its potential to capture the influence of processing conditions on layup quality is investigated.",

keywords = "Automated manufacturing, Automated fibre placement, Manufacturing-induced defects prediction, Thermoset prepreg composites",

author = "Yi Wang and Sarthak Mahapatra and Belnoue, \{Jonathan P\} and Dmitry Ivanov and Hallett, \{Stephen R\}",

note = "Funding Information: This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) through the Centre for Doctoral Training in Advanced Composites for Innovation and Science (grant no. EP/ L016028/1) and the platform grant “Simulation of new manufacturing Processes for Composite Structures (SIMPROCS)” (grant no. EP/ P027350/1). Yi Wang acknowledges the support from the China Scholarship Council. The authors acknowledge the Chair of Carbon Composites at the Technical University of Munich for providing their AFP simulation model that has inspired this work. Publisher Copyright: {\textcopyright} 2023 The Authors",

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AU - Wang, Yi

AU - Mahapatra, Sarthak

AU - Belnoue, Jonathan P

AU - Ivanov, Dmitry

AU - Hallett, Stephen R

N1 - Funding Information: This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) through the Centre for Doctoral Training in Advanced Composites for Innovation and Science (grant no. EP/ L016028/1) and the platform grant “Simulation of new manufacturing Processes for Composite Structures (SIMPROCS)” (grant no. EP/ P027350/1). Yi Wang acknowledges the support from the China Scholarship Council. The authors acknowledge the Chair of Carbon Composites at the Technical University of Munich for providing their AFP simulation model that has inspired this work. Publisher Copyright: © 2023 The Authors

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Y1 - 2023/7/20

N2 - Automated manufacturing of carbon fibre-reinforced polymer composites, such as automated fibre placement (AFP), is widely used in the aerospace industry. Due to the large number of physical and environmental phenomena involved and their (mathematical) nonlinearity, simulating the AFP process under varied processing conditions has, for a long time, been computationally out of reach. This paper discusses how recent advancements in the Finite Element (FE) simulation of steering-induced defects in AFP can allow virtual optimisation of the process prior to physical trials. First, efforts necessary to adequately characterise the material experimentally and constitutive models able to represent the observed behaviour are reviewed. The material models are then incorporated into a simulation platform developed in a commercial FE package. It is shown that the proposed virtual AFP platform has good predictive capabilities against experimental data available from literature. Its potential to capture the influence of processing conditions on layup quality is investigated.

AB - Automated manufacturing of carbon fibre-reinforced polymer composites, such as automated fibre placement (AFP), is widely used in the aerospace industry. Due to the large number of physical and environmental phenomena involved and their (mathematical) nonlinearity, simulating the AFP process under varied processing conditions has, for a long time, been computationally out of reach. This paper discusses how recent advancements in the Finite Element (FE) simulation of steering-induced defects in AFP can allow virtual optimisation of the process prior to physical trials. First, efforts necessary to adequately characterise the material experimentally and constitutive models able to represent the observed behaviour are reviewed. The material models are then incorporated into a simulation platform developed in a commercial FE package. It is shown that the proposed virtual AFP platform has good predictive capabilities against experimental data available from literature. Its potential to capture the influence of processing conditions on layup quality is investigated.

KW - Automated manufacturing

KW - Automated fibre placement

KW - Manufacturing-induced defects prediction

KW - Thermoset prepreg composites

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DO - 10.1016/j.compositesa.2023.107702

M3 - Article (Academic Journal)

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VL - 173

JO - Composites Part A: Applied Science and Manufacturing

JF - Composites Part A: Applied Science and Manufacturing

M1 - 107702

ER -

Modelling the Effect of Process Conditions on Steering-Induced Defects in Automated Fibre Placement (AFP)

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